Rail and Road Over Rail Bridge

Typical Engineering techniques followed in construction of "Rail and Road Over Rail Bridge" have been incorporated in this presentation.

1. Rail & Road Over Rail Bridge Client: RVNL(Rail Vikas Nigam Limited) Chennai. PMC: BARSYL Pvt. Ltd. Contractor: DCS Pvt. Ltd. Hyd. Presented By Harish Korutla ID No. B111804

2. Contents Introduction Substructure Superstructure Miscellaneous Items Conclusion References

3. Introduction As the transportation of goods become too difficult from Obulavaripalle to Krishnapatnam, Government had proposed new Broad Gauge (BG) line between Obulavaripalle and Venkatachalam Road junction-Construction of Rail and Road over Rail Bridge between Km. 93-95 near Venkatachalam Road junction Railway station between Guduru and Nellore crossing NH-5 at NH Km. 154/148 and Railway Km. 155/22-24 in Nellore district in South Central Railway. And it is undertaken by Delta Construction Systems Private Limited Hyderabad.

4. This project is an extract of new Railway line from Obulavaripalle of Cuddapah district to Krishnapatnam Port of Nellore district. An existing South Central Railway line crossing Obulavaripalle Railway station is shown in the figure below:

5. More precisely an overview or key plan can be plotted as follows:

6. Substructure Substructure can be defined as the union of structural elements which are in contact with the ground. The Structural elements of Substructure are listed and explained below. Pile Foundation Pile Caps Piers Abutments Pier Caps/Trestle Beams Pedestals Bearings

7. Pile Foundation Noticed that the soft rock exists after two or three layers of soil which explains the selection of foundation for transfer of super structural loads coming from the bridge onto the ground safely.

8. Pile Identification

9. Tests on Piles To assess the carrying capacity of the casted piles and to ensure the homogeneity, various advanced tests have been conducted. A third party GEOTIES INFRATECH PVT. LTD. have conducted three tests on the test pile. They are listed below: Initial Pile Load Test/Kent Ledge Load Test Dynamic load Test Pile Integrity Test

10. Initial Pile Load Test/Kent Ledge Load Test Loading applied on the pile head was measured by volumetric method. In this method sand bags were arranged on top of the platform which is made with 8mm thick MS plate. The plate rests on the secondary beams of ISMB 300. These 27 No’s ISMB 300 was resting on 7No’s of ISMB 600 and supported by solid bed on either of the pile. The total dead load available for the pile load test was about 1100MT.

11. Initial Pile Load Test/Kent Ledge Load Test

12. Dynamic load Test The basic purpose of high strain dynamic pile testing is to evaluate pile static capacity and its structural integrity using measurement of both force and velocity . Strain transducers and accelerometers are attached to the test pile. Strains induced under the impact of a heavy falling hammer from a pre-determined height are measured with the help of strain transducers attached to the pile, whereas accelerometers record the accelerations generated in the pile. The Pile Driving Analyzer(PDA) converts strain to force , and acceleration records are converted to velocities . By using measured velocities, they performed trial and error process in CAPWAP Software and computed forces in order to plot the graph between measured and computed forces. And subsequent results have been found out and assured by the Chief Engineer or Engineer In charge.

13. Pile Driving Analyzer

14. CAPWAP Software

15. CAPWAP RESULTS OF PILE: P4/8

16. Test results of Pile: p4/8

17. PILE INTEGRITY TEST The low strain Integrity testing is a Non-Destructive Integrity test method for foundation piles for the assessment of potential problems like cross sectional changes, honeycombing, Physical dimensions, continuity of pile and concrete quality. This testing requires the attachment of the highly sensitive accelerometer to the pile top with viscous material. After hammer impact downward compressive wave is generated travelling with wave speed “c”.

18. Pile Caps Design of Pile Cap is based on the code of practice IS: 2911 (Part 1/Sec2) – 1979 . Clear cover 75mm was maintained for Pile Caps by following the notes specified in drawings. Plan of the Pile Cap is shown below:

19. Piers Piers are compression members built as a major part of the bridge to carry the super structural loads coming from various structural elements like pier caps, pedestals, girders, deck slab and wearing coat, wheel axle loads etc. Piles are designated as P1, P2, P3, P4, P5, P6, P7, P8. P3, P7, P8 carry composite girders. P1, P2, P4, P5, P6 carry PSC girders. P2 lies in the median of the National Highway – 5. P2 details are shown in below figure

20. Abutments Abutments are the structural elements function for the load distribution onto the ground and backfill material or earthen embankment with the help of approach slabs. In this project, Abutments are designated as A-1 & A-2. While concreting return walls and abutment walls, they’ve provided weep holes with an arrangement of PVC Pipes covered with g eotextile material at one end to counteract clog formation.

21. Pier Caps/Trestle Beams Pier Caps generally treated as platforms for supporting pedestals, bearings, girders over it. Pier Caps are also known as “Trestle Beams ”. P1, P2, P3 trestle beams carry NH-5 composite girders. Similarly P7, P8 trestle beams carry Railway Span composite girders.

22. Pedestals Pedestals act like platforms for the placement of suitable bearings . M40 grade of concrete has been used and 30mm of clear cover has maintained . Supports for placing concrete are of special type (Wooden Box type material) and they were arranged.

23. Bearings The bearing is an element of superstructure which provides an interface between the superstructure and substructure . This interface is vital because superstructure undergoes dimensional changes and deformations due to various factors which are listed as follows: a) Thermal expansion/contraction b) Elastic deformation under live load c) Seismic forces d) Creep and shrinkage of concrete e) Settlement of supports f) Longitudinal forces – tractive / breaking g) Wind loads.

24. Types of BEARINGS i . Free Float Bearing of Capacity 248MT ii. Pin Metallic Guided Bearing of Capacity 18MT iii. Pin Fixed Bearing of Capacity 93-114MT iv. Free Float Bearing of Capacity 189MT v. Slide Guide Bearing of Capacity 178MT vi. Slide Guide Bearing of Capacity 189MT Pin Metallic Guided Bearing is shown in below figure.

25. Superstructure Superstructure can be defined as the union of structural elements which are not in contact with the ground, in other words it’s the structure lies in the space with the support of substructural elements . The Structural elements of Superstructure are listed and explained below. Girders Deck Slab

26. Girders Girders are structural members carry super structural loads and distribute to the substructure, from then, to the ground safely. PSC Girders Composite Steel Girders Cross Girders/Diaphragms

27. PSC Girders Firmly, Precast PSC Girders are casted at the site . After curing for 15days, stressing has been done and accordingly evaluated elongation so as to check with the specifications provided . Arrangement of the reinforcement and Cable profiling are shown in the below figure.

28. Composite steel Girders Composite girders are manufactured in the workshop namely PMG Structural’s Limited. As per the designed drawings, composite girders are manufactured and shipped to the site. Before going for the manufacture of composite girders, activities included like materials’ tests such as Physical dimensional check , Chemical analysis , Mechanical testing and etc. For the erection of composite girders, DTI Washer was used in the process of tightening the bolted connection.

29. Direct Tension Indicators The Direct Tension Indicators are special type of washers with indentations which get pressed when the tension is applied. DTIs are very good method of ensuring that the bolts are tightened properly, and shall be preferred over plain washers. Measuring the amount by which the indentations have been pressed indicate if the bolts have been tightened to the desired tension level.

30. Check for Tightening Number of Indicator positions Minimum number of Feeler gauge refusals* 4 3 5 3 6 4 7 4 8 5 9 5 * No more than 10% of the indicators in a connection bolt group shall exhibit full compression of the indicator.

31. cross Girders/Diaphragms Cross Girders/Diaphragms act like tie beams. Intermediate Diaphragms End Diaphragms Below picture is representing reinforcement inside an End Diaphragm.

32. Deck Slab Shear studs are provided on composite girders so as to prevent the sliding away of concrete . Ponding method of curing has been implemented for deck slabs, it’s showed in the following figure.

33. Miscellaneous Items Expansion Joints OHE Masts Drainage Walls

34. Expansion joint Expansion joints are meant for the allowance of thermal changes in the whole structural elements. Specifications and achieved conditions are overlapped for assurance.

35. OHE MASTS & dRAINAGE Over Head Electrical Masts are provided for carrying electrical wires and supply power. For every pier, there is a provision of OHE Masts. For that purpose, an extra cantilever portion is provided to facilitate the necessity of electricity. Drainage: To facilitate the drainage, drain spots are also mentioned in the drawing. While concreting the deck slab it is ensured that to provide PVC pipes.

36. WALLS Reinforced Parapet Walls Reinforced Ballast Retaining Walls

37. Conclusion Basically bridge is catalogued into two categories named as super structure and sub structure. Substructure consists of elements like foundation, columns or piers, pier caps, pedestals, bearings. Whereas Superstructure consists of structural elements like PSC girders, Composite girders, Cross girders, Deck Slab and miscellaneous items. As per the drawings, Work has done in a fully management plan.

38. References Maps from Survey of India L & T Ramboll Consulting Engineers Limited Designed Drawings Sanfield (India) Limited Bearings’ Drawings Geoties Infratech Private Limited Pile Test Results Contract Agreement for ROR Site Nellore Bridge Bearings for Railways Document IRC 83 Part 3 – Specifications for Bearings International Journal of Current Research of Academic review IS 14268:1995 Uncoated Stress Relieved Low Relaxation seven-ply strand for prestressed concrete Clause 8.5.6 of EN 1090-2 Annexure J of EN 1090-2 Clause 8.5.4 of EN 1090-2 Research Development and Standards Organization (RDSO) Guidelines for Railway Bridge Indian Roads Standards Substructure code Indian Roads Standards Superstructure code www.piledynamics.com RVNL Flyover Bridge Final Drawings Information from Site Reports Site Pictures at different stages of Works

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